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    Pressure Requirements: Flow Length

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    anirudha_jewalikar1
    There are several factors that influence injection pressure requirements during plastic part molding. Part design attributes like wall thickness and surface area can impact pressure needs, with thinner walls and more surface area requiring higher pressure. Mold design choices such as gate size and flow length also influence pressure, with smaller gates and longer flows necessitating higher pressure. Process conditions like fill time and melt temperature play a role as well, with shorter fill times and colder melts typically requiring more pressure. Material properties also must be considered, as resins with lower melt flow rates generally demand higher molding pressures. Proper part, mold, and process design can help optimize injection pressure levels.

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    Pressure Requirements: Flow Length

    Uploaded by

    anirudha_jewalikar1
    2K views43 pages
    There are several factors that influence injection pressure requirements during plastic part molding. Part design attributes like wall thickness and surface area can impact pressure needs, with thinner walls and more surface area requiring higher pressure. Mold design choices such as gate size and flow length also influence pressure, with smaller gates and longer flows necessitating higher pressure. Process conditions like fill time and melt temperature play a role as well, with shorter fill times and colder melts typically requiring more pressure. Material properties also must be considered, as resins with lower melt flow rates generally demand higher molding pressures. Proper part, mold, and process design can help optimize injection pressure levels.

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    There are several factors that influence injection pressure requirements during plastic part molding. Part design attributes like wall thickness and surface area can impact pressure needs, with thinner walls and more surface area requiring higher pressure. Mold design choices such as gate size and flow length also influence pressure, with smaller gates and longer flows necessitating higher pressure. Process conditions like fill time and melt temperature play a role as well, with shorter fill times and colder melts typically requiring more pressure. Material properties also must be considered, as resins with lower melt flow rates generally demand higher molding pressures. Proper part, mold, and process design can help optimize injection pressure levels.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    2K views43 pages

    Pressure Requirements: Flow Length

    Uploaded by

    anirudha_jewalikar1
    There are several factors that influence injection pressure requirements during plastic part molding. Part design attributes like wall thickness and surface area can impact pressure needs, with thinner walls and more surface area requiring higher pressure. Mold design choices such as gate size and flow length also influence pressure, with smaller gates and longer flows necessitating higher pressure. Process conditions like fill time and melt temperature play a role as well, with shorter fill times and colder melts typically requiring more pressure. Material properties also must be considered, as resins with lower melt flow rates generally demand higher molding pressures. Proper part, mold, and process design can help optimize injection pressure levels.

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    At a glance
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    Injection pressure is influenced by part design, mold design, process conditions, and material properties.

    Injection pressure is influenced by part design, mold design, process conditions, and material properties.

    Thicker walls and less surface area require higher injection pressure, while thinner walls and more surface area require lower injection pressure.

    Pressure

    Pressure Requirements

    P1

    P2

    Flow Length
    What Influences Injection
    Pressure?
    • Part Design
    • Mold Design
    • Process Conditions
    • Material Properties
    Part Design Impact
    • Wall Thickness

    Thin Part Thick Part

    Higher Lower
    Pressure Pressure
    Part Design Impact
    • Surface Area

    More Wall Less Wall


    Cooling & Cooling &
    Drag Force Drag Force

    Higher Lower
    Pressure Pressure
    Mold Design Impact
    • Gate Size
    Restrictive Generous
    Gate Gate

    Higher Lower
    Pressure Pressure
    Mold Design Impact
    • Flow Length (Gate Location)

    Long Flow Short Flow


    Length Length

    Higher Lower
    Pressure Pressure
    Process Impact
    • Fill Time

    Too Too Optimal


    Short Long Fill Time

    Higher Lower
    Pressure Pressure
    Slow vs. Fast Fill Time

    Thick Frozen Layer Thin Frozen Layer

    Melt Melt

    Long Fill Time Short Fill Time


    Low Injection Speed High Injection Speed
    Fill Time vs. Injection Pressure
    80
    Optimal Fill
    Maximum Injection

    60
    Pressure (MPa)

    Time Range

    40

    20

    0 4 8 12 16 20
    Fill Time (sec)
    Process Impact
    • Melt Temperature

    Colder Melt Hotter Melt

    Higher Lower
    Pressure Pressure
    Melt Temperature Affects Resin
    Viscosity
    Viscosity for Polycarbonate

    100
    Viscosity (lb ft-s/ft^2)

    590 F
    640 F
    10

    1
    1 10 100 1000 10000
    Shear Rate (1/s)
    Process Impact
    • Mold Temperature

    Colder Coolant Hotter Coolant


    Temperature Temperature

    Higher Lower
    Pressure Pressure
    Material Impact
    • Resin Flow Properties
    Low MFR Material High MFR Material
    W W

    Higher Lower
    Pressure Pressure
    Material Selection Affects
    Injection Pressure
    PMMA
    120 PP
    Maximum Injection

    100
    Pressure (MPa)

    80

    60

    40

    20

    0 4 8 12 16 20
    Fill Time (sec)
    How Does Area Affect Velocity?
    MFA @ time = t1
    MFA @ time = t2

    High MFV Low MFV


    time = t1 time = t2
    Types of Runner Systems
    Naturally Balanced Artificially Balanced
    Types of Runner Systems
    Cold Runners

    1
    1
    2

    2 3

    2-Plate Mold 3-Plate Mold


    Types of Runner Systems
    Hot Runners
    Cartridge Shut-Off
    Heater Pin
    Nozzle
    Frozen
    Layer
    Heater

    Gate Melt
    Cavity
    Melt
    Melt

    Insulated Internally Externally


    Heated Heated
    What is the Best Runner
    Diameter?
    • Allows the Mold to be Filled Quickly
    • Minimizes Scrap in the Runner
    • Delivers the Melt as Uniformly as Possible
    What is the Best Runner
    Diameter?
    800 For PS, ABS, SAN

    700 G: Weight (g)


    S: Nominal thickness (mm)
    600 D: Reference diameter (mm)
    500
    G(g)

    400

    300
    200
    S=1

    100
    1.5

    3.5

    4.5
    2.5

    5
    4
    2

    0
    2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5
    D’
    When To Use a Hot Runner
    System?
    • Long Runner Lengths (High Pressure Loss
    in Cold Runner)
    • Reduce or Eliminate Scrap in the Runner
    System
    • Minimize Cycle Time for Thin Walled Parts
    Determining the Best Gate
    Locations
    • Should Allow Part to Fill Within Target
    Pressure
    • Must Properly Place Weld Lines
    • Should Not Be Located in Structural Areas
    Determining the Number of
    Gates Needed
    • Dependent on Flow Length
    • Dependent on Part Thickness
    • Dependent on Resin Being Used
    • Should Promote a Large Process Window
    So What’s a Process Window?
    GE Lexan 101 @ 624 (F)
    650

    640
    Melt Temperature (F)

    630

    620

    610

    600

    590
    5000 10000 15000 20000

    Injection Pressure (psi)


    Thickness Change Affects the
    Process Window
    Flow Length = 5” Flow Length = 10”
    Center Gate End Gate
    650 650
    Melt Temperature (F)

    Melt Temperature (F)


    640 640

    630 630

    620 620

    610 610

    600 600

    590 590
    5000 10000 15000 20000 5000 10000 15000 20000
    Injection Pressure (psi) Injection Pressure (psi)
    Cooling Design
    • How Cooling Time Affects Cycle Time
    • How Wall Thickness Impacts Cooling Time
    • Considerations for a Good Cooling Design
    How Cooling Affects the Cycle
    Time
    Reduce Cooling Time
    Reduce Cycle Time
    Increase profits! Injection

    Mold Opening
    and Ejection Mold
    Cooling
    How Wall Thickness Impacts
    Cooling Time
    Cooling
    CoolingTime
    Time~~(Heaviest
    (HeaviestWall
    WallThickness)
    Thickness)2
    2

    Thermal
    ThermalDiffusivity
    Diffusivityof
    ofthe
    theMelt
    Melt

    Original Design Better Design


    Good Cooling vs. Bad Cooling

    Proper Better Part


    Cooling in Shorter Time

    Poor Poor Part


    Cooling in Longer Time
    Residual Stress
    • What Causes Residual Stress?
    • Unbalanced Residual Stress
    What Causes Residual Stress?
    Free
    Contraction

    Molten
    Heat Heat
    Polymer

    Frozen
    Layers
    Early Cooling
    Stage
    What Causes Residual Stress?
    Constrained
    Contraction

    Cooling
    Polymer

    Later Cooling
    Stage
    What Causes Residual Stress?
    Thermal Induced
    Residual Stresses
    Tensile (+)

    (-) Compressive

    Post-Molding
    Stage
    Unbalanced Residual Stress

    Low Cooling High Cooling


    Rate
    Heat Rate

    Heat
    Cooling
    Channel

    Early Cooling Stage:


    Uneven Cooling
    Unbalanced Residual Stress
    Tensile(+)

    (-)Compressive

    Post-Molding Stage: Asymmetrical


    Thermal-Induced Residual Stress
    Unbalanced Residual Stress

    Warped Part
    Shrinkage and Warpage
    • Why Does One Plastic Shrink Differently
    Than Another?
    • What Influences Shrinkage?
    • What Causes Part Warpage?
    • How to Minimize Warpage Problems
    What Influences Shrinkage?
    Shrinkage

    Melt Temperature

    Mold Temperature

    Injection Rate
    What Influences Shrinkage?
    Shrinkage

    Holding
    Pressure

    Holding Time

    Part Thickness
    What Causes Part Warpage?
    Hot

    Part

    Part Warps Toward


    Cold Hot Surface

    Hot

    Cold Part Warps Toward


    Hot Surface

    Unbalanced Cooling
    What Causes Part Warpage?
    High High Cooling Rate
    Shrinkage Low Crystallization Level

    Low Cooling Rate Warped Part


    High Crystallization Level

    Non-Uniform Wall Thickness


    What Causes Part Warpage?
    Unfilled
    Materials

    High Low Flow


    Gate Pressure Pressure Direction
    Low High
    Shrinkage Shrinkage
    Fiber
    Differential Fiber-Filled Orientation
    Shrinkage Materials

    Molecular and Fiber Orientation


    How to Minimize Warpage
    Problems
    • Avoid Large Pressure Variations
    – Wall Thickness Variation
    – Long Flow Lengths
    – Uneven Filling Pattern
    • Avoid Large Temperature Variations
    – Wall Thickness Variation
    – Unbalanced Cooling

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